US11207145B2 - Multi-cable medical instrument - Google Patents

Multi-cable medical instrument Download PDF

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US11207145B2
US11207145B2 US16/317,235 US201716317235A US11207145B2 US 11207145 B2 US11207145 B2 US 11207145B2 US 201716317235 A US201716317235 A US 201716317235A US 11207145 B2 US11207145 B2 US 11207145B2
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cable
cables
pulleys
piece
input
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US20190307522A1 (en
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Bram Gilbert Antoon Lambrecht
S. Christopher Anderson
Ladd T. Johnson
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Intuitive Surgical Operations Inc
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Intuitive Surgical Operations Inc
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Assigned to Intuitive Surgical Operations, Inc. reassignment Intuitive Surgical Operations, Inc. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ANDERSON, S. CHRISTOPHER, JOHNSON, LADD T., LAMBRECHT, BRAM GILBERT ANTOON
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B34/00—Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
    • A61B34/30—Surgical robots
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B34/00—Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B34/00—Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
    • A61B34/70—Manipulators specially adapted for use in surgery
    • A61B34/71—Manipulators operated by drive cable mechanisms
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/28—Surgical forceps
    • A61B17/29—Forceps for use in minimally invasive surgery
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B2017/00477—Coupling
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/28—Surgical forceps
    • A61B17/29—Forceps for use in minimally invasive surgery
    • A61B2017/2901—Details of shaft
    • A61B2017/2902—Details of shaft characterized by features of the actuating rod
    • A61B2017/2903—Details of shaft characterized by features of the actuating rod transferring rotary motion
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/28—Surgical forceps
    • A61B17/29—Forceps for use in minimally invasive surgery
    • A61B2017/2926—Details of heads or jaws
    • A61B2017/2927—Details of heads or jaws the angular position of the head being adjustable with respect to the shaft
    • A61B2017/2929—Details of heads or jaws the angular position of the head being adjustable with respect to the shaft with a head rotatable about the longitudinal axis of the shaft
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B34/00—Computer-aided surgery; Manipulators or robots specially adapted for use in surgery
    • A61B34/70—Manipulators specially adapted for use in surgery
    • A61B34/71—Manipulators operated by drive cable mechanisms
    • A61B2034/715—Cable tensioning mechanisms for removing slack
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B90/00—Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups A61B1/00 - A61B50/00, e.g. for luxation treatment or for protecting wound edges
    • A61B90/36—Image-producing devices or illumination devices not otherwise provided for
    • A61B90/37—Surgical systems with images on a monitor during operation
    • A61B2090/371—Surgical systems with images on a monitor during operation with simultaneous use of two cameras

Definitions

  • Robotically controlled instruments such as employed for minimally invasive medical procedures often employ a tool or end effector or other manipulation element at the distal end of an extended instrument shaft.
  • the terms “robot” or “robotically” and the like include teleoperation or telerobotic aspects.
  • the instrument shaft and the distal tool generally have small diameters, often less than a centimeter, to minimize the size of incisions or natural lumens needed for insertion of the instrument.
  • the distal tools are often remotely operated or actuated via thin drive members (e.g., tendons or rods) that extend between the distal tool and a transmission, sometimes referred to as the backend mechanism of the instrument.
  • the backend mechanism of a replaceable instrument is generally configured to removably couple to actuators (e.g., a motor pack) in a docking port of a robot.
  • the robot can then control the actuators and apply force through the backend mechanism to the drive members and through the drive members to the distal tool of the instrument.
  • Medical instruments that have many degrees of freedom of movement typically require many drive members, and backend mechanisms that accommodate the transition from the layout of a docking port of a robot to the layout of the drive members in the instrument shaft can be complex and difficult to assemble.
  • a medical instrument may provide efficient routing of actuation cables and relatively simple assembly process for complex medical instruments.
  • a medical instrument including a chassis, input spindles mounted in the chassis, upper and lower cables wound around the input spindles, and an instrument shaft extending from the chassis and including a mechanical structure providing multiple degrees of freedom of motion.
  • the upper and lower cables may connect to the mechanical structure so that rotations of the input spindles actuate respective degrees of freedom.
  • Lower pulleys may be mounted at a first level to receive the lower cables from the input spindles and to redirect the lower cables toward the instrument shaft.
  • Upper pulleys may be mounted at a second level to receive the upper cables from the input spindles and redirect the upper cables through the first level and toward the instrument shaft.
  • the method may include: mounting lower pulleys on a first piece of a chassis of the medical instrument; feeding lower cables from an instrument shaft of the medical instrument over the lower pulleys; attaching a second piece of the chassis to the first piece so that at least portions of the lower cables are between the lower pulleys and the second piece; mounting upper pulleys in positions such that the second piece is between the upper pulleys and the lower pulleys; and feeding upper cables from the instrument shaft over the upper pulleys.
  • Yet another specific implementation is a medical instrument including input spindles, lower cables respectively wound around the input spindles, upper cables respectively wound around the input spindles, and an instrument shaft extending from a chassis in which the input spindles are mounted.
  • a mechanical structure on the instrument shaft has multiple degrees of freedom of motion, and the upper and lower cables connect to the structure such that rotations the input spindles respectively actuate the degrees of freedom.
  • the lower or upper cables may extend between the input spindles and the instrument shaft without crossing, and paths of the other upper or lower cables cross between the input spindles and the instrument shaft.
  • the crossing in one set of cables may allow the upper cable and the lower cable that wrap around the same input spindle to be more efficiently directed toward locations on opposite sides of a central axis of the instrument shaft, which may improve mechanical efficiency of actuation of the mechanical structure.
  • FIG. 1 shows an implementation of a medical system employing removable instruments.
  • FIGS. 2A and 2B show side and top views of an example implementation of a medical instrument.
  • FIG. 4 is a cross-sectional view illustrating a routing of cables relative to a chassis and other structures in an example implementation of a backend mechanism of a medical instrument.
  • FIGS. 6A, 6B, and 6C illustrate a pulley structure created during an assembly process for a backend mechanism that routes cables between an instrument shaft of a medical instrument and a set of input spindles around which the cables wrap.
  • FIG. 6D shows a cross-section of a portion of an example implementation of a backend mechanism and illustrates how pieces of a chassis may be fit close to a pulley to prevent cable derailment.
  • a backend mechanism of a robotically controlled medical instrument routes cables from multiple input spindles to an instrument shaft of the instrument and employs a routing that allows simple assembly using few components.
  • Cables and associated pulleys in an instrument may be particularly grouped by level or height relative to the instrument shaft, and lower cables may be fit on pulleys mounted in a lower chassis piece before a next, higher chassis piece and pulleys for upper cables are attached to the lower chassis piece.
  • a two-level system is particularly effective in a self-antagonistic system in which each input spindle has a pair of two associated cables that are wrapped around the input spindle in opposite directions and at different heights so that one cable pays in in one direction and the other cable pays out in an opposite direction as the spindle rotates.
  • the cable routing leaves space for other components of the backend of a medical instrument, for example, to allow control or actuation of instrument shaft roll, grip drive, electrical connectors, and latching mechanisms that attach the backend mechanism to a robot.
  • the cable routing can also position cables paired in opposition in the instrument shaft, so that the paired cables can efficiently actuate opposite directions of motion of a degree of freedom of the instrument.
  • FIG. 1 shows an example of a medical system 100 using replaceable medical instruments 110 .
  • System 100 which may, for example, be a da Vinci® Surgical System commercialized by Intuitive Surgical, Inc., may particularly employ multiple surgical instruments 110 , each of which is removably mounted in a docking port 120 on a manipulator arm 130 of a robot 140 .
  • a sterile barrier (not shown) including a drape and adaptors for instruments 110 may be between instruments 110 and robot 140 , so that robot 140 , including manipulator arms 130 and docking ports 120 , is outside a sterile environment for a patient. Accordingly, robot 140 may not need to be sterilized between medical procedures.
  • instruments 110 which may be used in the sterile environment and may contact the patient, are compact and removable so that instruments 110 may be sterilized or replaced between medical procedures performed using system 100 .
  • Instruments 110 may vary in structure and purpose but may still be interchangeable, so that instruments 110 mounted in docking ports 120 of robot 140 can be selected for a particular medical procedure or changed during a medical procedure to provide the clinical functions needed.
  • Each instrument 110 generally includes an end effector or distal tool 112 , an instrument shaft 114 , and a backend mechanism 116 .
  • Distal tools 112 may have different designs to implement many different functions.
  • distal tools 112 for different instruments 110 may have many different shapes or sizes and may include forceps, graspers, scalpels, scissors, cautery tools, or needle drivers to name a few possibilities, and instruments 110 having different distal tools 112 may be mounted on different arms 130 of robot 140 and may work cooperatively in the same work site.
  • An endoscopic camera for example, a stereoscopic camera, can also be mounted on an arm to provide visual information, particularly images, of the work site in which distal tools 112 of instruments 110 may be operating.
  • Docking ports 120 may include actuators, such as drive motors, that provide mechanical power for actuation of mechanical structures in instruments 110 , drive couplings that connect the actuators to inputs of instruments 110 , and systems for establishing and maintaining a sterile barrier between instruments 110 and the rest of medical system 100 .
  • Docking ports 120 may additionally include an electrical interface to provide power to instruments 110 or for communication with instruments 110 , for example, to identify the type of instrument 110 in a docking port 120 , to access parameters of instruments 110 , or to receive information from sensors in instruments 110 .
  • the electrical interface may convey to robot 140 measurements such as measurements of the position, orientation, or pose of distal tool 112 and instrument shaft 114 of an instrument 110 .
  • a computer system which may be connected to or part of robot 140 and connected to a user interface device (not shown), may receive the measurements from instrument 110 and receive user commands from a surgeon or other medical personnel and may execute software that controls arms 130 and drive motors in docking ports 120 as needed to operate instruments 110 according to the user commands.
  • FIGS. 2A and 2B illustrate an example implementation of a medical instrument 110 .
  • FIG. 2A particularly shows a perspective view of an implementation having a tool 112 at the distal end of instrument shaft 114 and shows instrument shaft 114 extending from backend mechanism 116 .
  • distal tool 112 and instrument shaft 114 have six degrees of freedom of movement relative to backend mechanism 116 .
  • the six degrees of freedom correspond to: pitch and yaw rotations of a distal portion of tool 112 about two respective perpendicular axes 201 and 202 associated with a first joint mechanism 211 (also called “first joint 211 ”); pitch and yaw rotations or movement of jaws 213 relative to two respective perpendicular axes 203 and 204 associated with a second joint mechanism 212 (also called “second joint 212 ”; the joints 211 , 212 are sometimes referred to as “wrists”); opening or closing movement 205 of jaws 213 for “grip” actuation; and “roll” rotations of instrument shaft 114 about its central length axis 206 .
  • Other instruments may have more, fewer, or different degrees of freedom of movement.
  • Backend mechanism 116 as shown in FIG. 2B has six input spindles 221 to 226 with engagement features that are shaped and positioned to engage actuators, e.g., drive motors, in a docking port of a robot.
  • actuators e.g., drive motors
  • each input spindle 221 to 226 may be coupled for actuation of a different degree of freedom of movement of the instrument, so that the robot can identify and use the correct actuator or actuators to rotate the spindle or spindles that exercise desired degrees of freedom of motion.
  • the assignment input spindles 221 to 226 to corresponding degrees of freedom must be known to the robot but can be otherwise defined by an arbitrary standard or convention.
  • input spindle 226 may couple to a roll mechanism that connects to a proximal end of instrument shaft 114 for rotation of instrument shaft 114 about its length axis 206 when input spindle 226 rotates.
  • Input spindles 221 to 225 may couple to drive members (not shown) such as cables or rods extending though instrument shaft 114 to distal tool 112 , so that the actuators in the robot can rotate input spindles 221 to 225 to control a distal mechanism including joints 211 and 212 and jaws 213 . More specifically, in an exemplary implementation, rotation of input spindle 221 may control rotation or actuation of a distal portion of tool 112 about an axis 201 .
  • Rotation of input spindle 222 may control rotation about an axis 202 .
  • Rotation of input spindle 223 may control rotation about an axis 203 for yaw actuation of jaws 213
  • rotation of input spindle 224 may control rotation about an axis 204 for pitch actuation of jaws 213 .
  • rotations of input spindles 221 to 226 may correspond to motion that is different from or more complex than simple rotations of structures about axes.
  • input spindle 225 may be coupled to jaws 213 through a push-pull rod for actuation of gripping with jaws 213 .
  • the mechanism in tool 112 may couple a proximal portion of joint 212 to a distal portion of joint 211 for parallelogram motion, while the distal portion of joint 212 may move independently.
  • FIG. 3 shows selected elements within an implementation of the backend mechanism 116 of FIGS. 2A and 2B and particularly illustrates a routing in backend mechanism 116 of cables that run through instrument shaft 114 and connect to joints 211 and 212 .
  • the term “cable” is used herein in a broad sense to include any tendon-like structure.
  • a length of cable in a medical instrument may include sections of different materials or different characteristics.
  • a cable may include, for example, a stranded section where flexibility in the cable is desired (e.g., where the cable winds around a spindle, capstan, or pulley) and may include a more rigid section (e.g., a tube or rod) to limit stretching where less bending of the cable is needed.
  • FIG. 1 shows selected elements within an implementation of the backend mechanism 116 of FIGS. 2A and 2B and particularly illustrates a routing in backend mechanism 116 of cables that run through instrument shaft 114 and connect to joints 211 and 212 .
  • Input spindles 221 , 222 , 223 , and 224 are for actuation of degrees of freedom associated with respective axes 201 , 202 , 203 , and 204 , and each input spindles 221 , 222 , 223 , and 224 includes a pair of capstans around which a pair of actuation cables are wrapped.
  • an upper capstan 231 A and a lower capstan 231 B may be fixed on an axle of input spindle 221 so that both capstans 231 A and 231 B rotate with rotation of input spindle 221 .
  • a cable 241 A wraps in one direction (e.g., clockwise or counterclockwise) around capstan 231 A, and a cable 241 B wraps in the opposite direction (e.g., counterclockwise or clockwise) around capstan 231 B.
  • Cable 241 A extends from upper capstan 231 A to an upper pulley 251 that directs cable 241 A toward instrument shaft 114 .
  • cable 241 B extends from lower capstan 231 B to a lower pulley 261 that directs cable 241 B toward instrument shaft 114 .
  • Cables 241 A and 241 B extend from respective pulleys 251 and 261 through a guide 280 , into instrument shaft 114 , and through instrument shaft 114 to connect to actuated joint mechanism 211 , so that pulling cable 241 A or 242 B rotates a distal portion of mechanism 211 (and distal portions of tool 112 ) about axis 201 .
  • the positions of pulleys 251 and 261 and the shape of guide 280 may position cables 241 A and 241 B on opposite sides of the center or length axis 206 of instrument shaft 114 , which may allow cable 241 A to efficiently drive motion of mechanism 211 in one direction or sense about axis 201 and also allow cable 241 B to efficiently drive motion of mechanism 211 in an opposite direction or sense about axis 201 .
  • Each input spindle 222 , 223 , or 224 similarly includes an axle through a pair of capstans 232 A and 232 B, 233 A and 233 B, or 234 A and 234 B around which a pair of cables 242 A and 242 B, 243 A and 243 B, or 244 A and 244 B wrap in opposite directions, and cables 242 A, 242 B, 243 A, 243 B, 244 A, and 244 B pass over respective pulleys 252 , 262 , 253 , 263 , 254 , and 264 and run through guide 280 and instrument shaft 114 .
  • cables 242 A and 242 B connect to joint mechanism 211
  • cables 243 A, 243 B, 244 A, and 244 B connect to joint mechanism 212 .
  • Each pair of cables 242 A and 242 B, 243 A and 243 B, and 244 A and 244 B as described above includes one cable wound in one direction (e.g., clockwise) about an input spindle 221 , 222 , 223 , or 224 and another cable wound in the other direction (e.g., counterclockwise) around the input spindle 221 , 222 , 223 , or 224 , so that rotation of an input spindle 221 , 222 , 223 , or 224 pulls in one cable while paying out another cable.
  • one direction e.g., clockwise
  • another cable wound in the other direction e.g., counterclockwise
  • instrument 110 may employ self-antagonistic actuation in which each pair of cables 241 A and 2416 , 242 A and 242 B, 243 A and 243 B, or 244 A and 244 B controls a corresponding degree of freedom of movement, e.g., rotations about axes 201 , 202 , 203 , or 204 , of the instrument.
  • Non-antagonistic cable actuation may be used in some embodiments (e.g., one cable per spindle).
  • mechanisms 211 and 212 are wrists or joints that each provide two degrees of freedom of movement. Many other mechanisms can provide one or more degrees of freedom of movement and may be connected so that one or more pairs of cables can respectively actuate the one or more degrees of freedom.
  • An actuated mechanism may, for example, include a mechanical linkage with a link that is rotatable about a pivot, and a pair of cables may be connected to rotate the link in opposite directions relative to the pivot.
  • actuated mechanisms may be any structure, e.g., a linkage, a slide, or a flexure, capable of being moved/actuated in opposite directions. For each pair of cables, pulling one cable may drive actuation of the corresponding degree of freedom in one direction or sense, and pulling the other cable in the pair may drive actuation of the corresponding degree of freedom in an opposite direction or sense.
  • Routing of cables 241 A, 242 A, 243 A, and 244 A employs upper pulleys 251 , 252 , 253 , and 254 to receive cables 241 A, 242 A, 243 A, and 244 A from upper capstans 231 A, 232 A, 233 A, and 234 A and employs lower pulleys 261 , 262 , 263 , and 264 to receive cables 241 B, 242 B, 243 B, and 244 B from respective lower capstans 231 B, 232 B, 2336 , and 234 B.
  • Upper pulleys 251 , 252 , 253 , and 254 may all be positioned at about the same common height, while lower pulleys 261 , 262 , 263 , and 264 may all be positioned at about another common height that differs from the common height of upper pulleys 251 , 252 , 253 , and 254 . This allows the pulleys to be captured in stacked blocks or chassis pieces as described further below.
  • upper pulleys 251 , 252 , 253 , and 254 and lower pulleys 261 , 262 , 263 , and 264 may also be simplified by pairing pulleys to independently spin on shared axles. Using pulleys that share an axle may allow faster assembly, because multiple pulleys can be added to a structure by attaching a single axle.
  • input spindles 221 , 222 , 223 and 224 are arranged in a rectangular array, e.g., in rows and columns, and paths of cables from input spindles in the same row to locations over instrument shaft 114 are roughly parallel.
  • Pulley axles 271 to 274 may also be angled according to exit directions of the cables from the input spindles 221 to 224 and relative to the central axis 206 of instrument shaft 114 .
  • axle 271 may be turned about a first axis (e.g., an axis parallel to the axles of input spindles 221 to 224 ) to minimize the fleet angles at pulleys 251 and 253 of cables 241 A and 243 A from input spindles 221 and 223 .
  • Axle 271 may be turned about a second axis (e.g., an axis approximately parallel to the portion of cables 241 A and 243 A between pulleys 251 and 253 and capstans 231 A and 233 A) so that the portion of cables 241 A and 243 A between pulleys 251 and 253 and guide 280 converge toward guide 280 and instrument shaft 114 .
  • the angling of axles 271 to 274 may reduce the average fleet angle for entry and exit of the cables from the upper and lower pulleys and thereby reduce friction and wear.
  • Axles 271 to 274 may further be positioned relative to input spindles 221 to 224 and instrument shaft 114 to minimize wrap angles across sliding surfaces on the pulleys.
  • the positions of the pulleys may be further refined according to the desired cable paths exiting guide 280 .
  • redirection of any cable passing through guide 280 should only cause rubbing on the resilient surface (e.g., a metal portion) of guide 280 and not a softer surface (e.g., a plastic portion) of guide 280 .
  • the wrap angle across guide 280 should also be small so that the friction and sawing action any cable against guide 280 is small.
  • the cable path should further be relatively direct so that length of stranded cable does not negatively affect the overall stiffness of the drive train between the corresponding input spindle and the actuated mechanism.
  • the stranded sections of cables tend to stretch more than the rigid hypotube sections used in some embodiments.
  • the separations between input spindles 221 to 224 may be considerably larger than the diameter of instrument shaft 114 into which the cables need to be directed. Accordingly, the paths of the cables need to converge between input spindles 221 to 225 and instrument shaft 114 .
  • the cables also should not rub against each other or against any other structures in backend mechanism 116 .
  • cables 241 A, 241 B, 242 A, 242 B, 243 A, 243 B, 244 A, and 244 B around the input spindles in the illustrated implementation are chosen so that cables at one level (e.g., lower cables 241 B, 242 B, 243 B and 244 B) emerge from inside the array of input spindles 221 to 224 , and cables at other levels(e.g., upper cables 241 A, 242 A, 243 A and 244 A) emerge from an outer edge of the array of input spindles.
  • cables at one level e.g., lower cables 241 B, 242 B, 243 B and 244 B
  • cables at other levels e.g., upper cables 241 A, 242 A, 243 A and 244 A
  • Lower cables 241 B, 242 B, 243 B and 244 B which emerge from inside an area of the input spindle array, can directly converge at a relatively small angles toward instrument shaft 114 without interfering with each other or rubbing against other structures, such as input spindles 223 or 224 .
  • Upper cables 241 A, 242 A, 243 A and 244 A which emerge from the outer edge of input spindles 221 to 224 , have crossing paths, which increases the angle of convergence.
  • upper cables 241 A and 243 A which emerge from input spindles 221 and 223 , cross over upper cables 242 A and 244 A, which emerge from input spindles 222 and 224 .
  • upper pulleys 251 and 253 which are within the same level group as upper pulleys 252 and 254 , although having a generally common height may be staggered in height (e.g., so that cables 241 A and 243 A can cross over cables 242 A and 244 A without rubbing).
  • the larger angle of convergence provided by the crossing pattern allows cables 241 A and 242 A to pass from outer edges of input spindles 221 and 222 through the gap between input spindles 223 and 224 .
  • the crossing pattern also allows pulleys 251 and 253 , which receive cables 241 A and 243 A, to be farther from pulleys 252 and 254 , which receive cables 242 A and 244 A, than pulleys 261 and 263 are from pulleys 262 and 264 .
  • the wider spacing of upper pulleys 251 to 254 allows routing cables 241 A to 244 A toward instrument shaft 114 without interference from lower pulleys 261 to 264 or cables 241 B to 244 B.
  • Crossing one level of cables in this fashion also allows positioning of cables that wrap about the same input spindle and that are therefore paired for actuation of the same degree of freedom in opposition in instrument shaft 114 , which may permit efficient connection of the pair of cables to an actuated mechanism.
  • a crossing cable pattern may further reduce the space needed to accommodate the required splay.
  • the cable routing can position pulleys so that the cables do not rub on each other or on neighboring input spindles and do not require additional intermediary idler pulleys.
  • FIG. 4 shows a cross-sectional view of internal structure in an example implementation of a backend mechanism 116 .
  • backend mechanism 116 may include a chassis 500 with a central support structure 410 that extends between rows of input spindles 221 , 222 , 223 , and 224 .
  • the routing of cables 241 A to 244 A or 241 B to 244 B allows use of central support structure 410 to strengthen chassis 500 without interfering with cables 241 A to 244 A or 241 B to 244 B.
  • the cable routing also causes cables 241 A to 244 A or 241 B to 244 B to converge sufficiently to pass between input spindles 225 and 226 , through an opening in a linkage 420 for actuation of jaws 213 , and through an opening in a linkage 430 used for actuation of rotation about instrument shaft axis 206 .
  • This configuration with support structure 410 in the center of backend mechanism 116 opens up access to input spindles 221 , 222 , 223 , and 224 from around the perimeter of chassis 500 , for example, to attach and wrap cables 241 A to 244 A or 241 B to 244 B on capstans 231 A to 234 A and 231 B to 234 B and to tighten capstan clamping screws during assembly of backend mechanism 116 .
  • FIG. 5 shows an expanded view of some of the components in an implementation of a medical instrument with a multi-piece chassis 500 for a backend mechanism 116 .
  • Chassis 500 includes pieces 510 , 520 , 530 , 540 , 550 and 560 that may be snapped together during an assembly process.
  • a proximal end of instrument shaft 114 may be inserted in a bearing system in chassis piece 510 , at which point cables, e.g., cables 241 A to 244 A and 241 B to 244 B, which are attached to the distal tool of the instrument extend from instrument shaft 114 .
  • Chassis pieces 530 and 520 are separate to allow for the assembly of linkage 420 that couples to input spindle 525 and is employed for grip actuation in the exemplary implementation.
  • Chassis piece 530 has an upper portion shaped to hold axles 273 and 274 for lower pulleys that guide the actuation cables and redirect the actuation cables toward the instrument shaft. As shown in FIG. 6A , lower pulleys 263 and 261 on axle 273 may be mounted in slots formed in chassis piece 530 . Similarly, lower pulleys 262 and 264 on axle 274 are mounted in another set of slots in chassis piece 530 .
  • Lower cables 241 B, 242 B, 243 B, and 244 B which extend from instrument shaft 114 , may be seated in grooves on respective lower pulleys 261 , 262 , 263 , and 264 and threaded through openings in chassis piece 530 so that proximal ends of lower cables 241 B, 242 B, 243 B, and 244 B are near features 524 where input spindles 221 to 224 will reside.
  • Chassis piece 530 and 540 may be shaped to provide a close fit between chassis piece 540 and pulleys 261 to 264 so that cables 241 B, 242 B, 243 B, and 244 B are not easily derailed.
  • Upper pulleys 251 and 253 on axle 272 and upper pulleys 252 and 254 on axle 271 may be mounted in slots created by the combination of chassis pieces 530 and 540 .
  • the slot into which axle 271 fits may be at slightly different level from the slot into which axle 272 fits so that the upper cables can cross as described above.
  • Upper cables 241 A, 242 A, 243 A, and 244 A may be seated on respective upper pulleys 251 , 252 , 253 , and 254 and threaded through openings in chassis 500 so that proximal ends of upper cables 241 A, 242 A, 243 A, and 244 A are also near features 524 .
  • a chassis piece 550 connects to chassis pieces 530 and 540 as shown in FIG. 6C and may be shaped to provide a close fit to upper pulleys 251 to 254 so that upper cables 241 A, 242 A, 243 A, and 244 A are not easily derailed.
  • 6D particularly shows a cross-sectional view illustrating how chassis piece 550 when mounted on pieces 530 and 540 may be close fit to pulley 251 so that a gap 545 between chassis piece 550 and pulley 251 is narrower than the thickness of cable 241 A on pulley 251 .
  • cable 241 A fits into the grove in pulley 251 and cannot slip through gap 545 .
  • a chassis piece 560 snaps onto or otherwise connects to one or more of chassis pieces 520 , 530 , and 550 .
  • the top of chassis piece 560 is shaped to fit a docking port of a robot and includes features 564 that are shaped and located to hold the engagement features of input spindles 221 to 224 of the instrument.
  • chassis 500 may capture input spindles 221 to 224 between features 564 on chassis piece 560 and features 524 on chassis piece 520 .
  • Each input spindle may include an axle and a pair of capstans, e.g., upper capstans 231 A to 234 A and lower capstans 231 B to 234 B, which are initially free to rotate relative to each other.
  • the loose proximal ends of the actuation cables near features 524 may be attached to the corresponding one of capstans 231 A to 234 A or 231 B to 234 B.
  • Each capstan can then be independently rotated to wind the attached cable in the desired direction and to take up slack and provide a desired pre-tension in the attached cable.
  • the capstans can be clamped or locked in place on the axle of the input spindle, e.g., by tightening a clamping screw.
  • Other structures such as release levers comprising structure 440 of FIG. 4 may wrap around the outside of the actuation structure and cables and may be installed after assembly of the input spindles and routing of cables.
  • Co-filed U.S. Pat. App. No. 62/362,454 (filed Jul. 14, 2016), entitled “INSTRUMENT RELEASE”, describes structures such as release levers comprising structure 440 in more detail and is hereby incorporated by reference in its entirety.
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